US11840404B2 - Roller plate assembly - Google Patents
Roller plate assembly Download PDFInfo
- Publication number
- US11840404B2 US11840404B2 US17/520,847 US202117520847A US11840404B2 US 11840404 B2 US11840404 B2 US 11840404B2 US 202117520847 A US202117520847 A US 202117520847A US 11840404 B2 US11840404 B2 US 11840404B2
- Authority
- US
- United States
- Prior art keywords
- roller
- openings
- base plate
- group
- plate assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active, expires
Links
- 230000000712 assembly Effects 0.000 claims description 15
- 238000000429 assembly Methods 0.000 claims description 15
- 229920006324 polyoxymethylene Polymers 0.000 claims description 6
- 229930040373 Paraformaldehyde Natural products 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- -1 polyoxymethylene Polymers 0.000 claims description 5
- 238000005007 materials handling Methods 0.000 claims 9
- 239000000463 material Substances 0.000 description 17
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 239000002991 molded plastic Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910001094 6061 aluminium alloy Inorganic materials 0.000 description 1
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 241001417935 Platycephalidae Species 0.000 description 1
- 229930182556 Polyacetal Natural products 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 1
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002866 paraformaldehyde Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G39/00—Rollers, e.g. drive rollers, or arrangements thereof incorporated in roller-ways or other types of mechanical conveyors
- B65G39/10—Arrangements of rollers
- B65G39/12—Arrangements of rollers mounted on framework
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G13/00—Roller-ways
- B65G13/11—Roller frames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G39/00—Rollers, e.g. drive rollers, or arrangements thereof incorporated in roller-ways or other types of mechanical conveyors
- B65G39/02—Adaptations of individual rollers and supports therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G39/00—Rollers, e.g. drive rollers, or arrangements thereof incorporated in roller-ways or other types of mechanical conveyors
- B65G39/02—Adaptations of individual rollers and supports therefor
- B65G39/04—Adaptations of individual rollers and supports therefor the rollers comprising a number of roller forming elements mounted on a single axle
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/02—Articles
- B65G2201/0235—Containers
Definitions
- the invention relates generally to material handling systems and, more particularly, to roller plate assemblies for material handling systems.
- Material handling systems such as those used for moving boxes or packages, often have a first conveyor system at one level and a second conveyor system at a second, lower level.
- Roller mat assemblies may be used to allow the boxes or packages to move between the first (higher) conveyor and the second (lower) conveyor. In some respects, the roller mat assembly serves as a transition between the first conveyor and the second conveyor.
- a roller mat assembly is static and does not have a moveable conveyor belt.
- the roller mat assembly may have an injection molded plastic base plate and a series of rollers affixed to the base plate. As a box or package leaves the end of the first (upper) conveyor system, it contacts the rollers and moves down the roller mat assembly largely contacting the tops of the rollers until the box or package reaches the end of and is transported away by the second (lower) conveyor system.
- a roller mat assembly is generally angled at least 8 degrees from the horizontal so that a box or package may move over the rollers unassisted, except for gravity. Larger angles may be used when the height difference between the first conveyor system and second conveyor system is greater and/or the spacing between the end of the first conveyor system and the end of the second conveyor system is shorter. When the angle is higher and heavy boxes or packages fall off the end of the first conveyor system, the heavy boxes or packages may apply a significant force on the roller mat assembly and especially the injection molded plastic base plate. Over time, the injection molded plastic base plate may fracture/break, develop cracks/holes, and disable the rollers in the base plate.
- the boxes or packages may stop on the roller mat assembly and create a jam as additional boxes or packages are discharged from the first conveyor system onto the roller mat assembly.
- Such a jam often requires that the first conveyor system be shut down and the jam manually cleared.
- jams of boxes or packages may become more and more frequent as the condition of the damaged section(s) worsens.
- the roller mat assembly becomes so damaged that jams become too frequent and the roller mat assembly must be replaced.
- Replacing the roller mat assembly requires that the first and second conveyor systems be shut down, which causes a great disruption to the material handling capacity of the facility.
- a roller plate assembly includes a base plate with a plurality of openings distributed along a length and a width of the base plate.
- the base plate has an upper surface and a lower surface.
- the roller plate assembly includes at least two cross supports coupled to the lower surface of the base plate and at least two roller shafts spaced apart and extending at least partially through the at least two cross supports and extending in the width direction of the base plate.
- the roller plate assembly further includes a plurality of rollers rotatably mounted to the at least two roller shafts, each roller disposed within a corresponding one of the plurality of openings and configured to project at least partly over the upper surface of the base plate.
- the plurality of rollers are configured to allow a package to move across the plurality of rollers from a first edge of the roller plate assembly to a second edge of the roller plate assembly in the length direction of the base plate.
- the plurality of openings in the base plate may include a first group of openings where each opening thereof is configured to accommodate a single roller and a second group of openings where each opening thereof is configured to accommodate at least two rollers.
- the first group of openings and second group of openings may form an array of openings in the base plate extending in the length direction and width direction of the base plate.
- the array of openings may be configured such that the first group of openings are interposed between the second group of openings in the length direction.
- the array of openings may be configured such that the first group of openings are interposed between the second group of openings in the width direction.
- the array of openings may be configured such that the first group of openings are interposed between the second group of openings in both the length direction and the width direction.
- the base plate may be made of aluminum and the plurality of rollers may be made of polyoxymethylene.
- the roller plate assembly further includes an additional or second roller plate assembly like the first roller plate assembly.
- Each base plate of each roller plate assembly includes opposing side flanges extending along the width of each base plate.
- the side flange of one of the base plates of one roller plate assembly is configured to be connected to a corresponding side flange of the base plate of the other one of the roller plate assemblies.
- the at least two cross supports are disposed at opposing ends of the base plate and the roller plate assembly further includes at least an additional cross support disposed between the at least two cross supports and coupled to the lower surface of the base plate.
- the at least two roller shafts extend through the additional cross support and only partially through the at least two cross supports.
- the plurality of rollers are free of bushings or bearings.
- the invention also contemplates a material handling system that includes a first conveyor system having a discharge end, a second conveyor system spaced downstream from the first conveyor system, the second conveyor system having a receiving end.
- the material handling system also includes at least one roller plate assembly disposed between the discharge end of the first conveyor system and the receiving end of the second conveyor system.
- the roller plate assembly includes a base plate with a plurality of openings distributed along a length and a width of the base plate.
- the base plate has an upper surface and a lower surface.
- the roller plate assembly includes at least two cross supports coupled to the lower surface of the base plate and at least two roller shafts spaced apart and extending at least partially through the at least two cross supports and extending in the width direction of the base plate.
- the roller plate assembly further includes a plurality of rollers rotatably mounted to the at least two roller shafts, each roller disposed within a corresponding one of the plurality of openings and configured to project at least partially over the upper surface of the base plate.
- the plurality of rollers are configured to allow a package to move across the plurality of rollers from a first edge of the roller plate assembly to a second edge of the roller plate assembly in the length direction of the base plate.
- the roller plate assembly of the material handling system may include all the features in the various embodiments described herein.
- the material handling system may further include an additional or second roller plate assembly like the first roller plate assembly.
- Each base plate of each roller plate assembly includes opposing side flanges extending along the width of each base plate.
- the side flange of one of the base plates of one roller plate assembly is configured to be connected to a corresponding side flange of the base plate of the other one of the roller plate assemblies.
- FIG. 1 is a schematic representation of a material handling system with a roller plate assembly.
- FIG. 2 is perspective view of a roller plate assembly according to an embodiment of the invention.
- FIG. 3 is a partially disassembled, perspective view of the roller plate assembly of FIG. 2 .
- FIG. 4 is partial bottom perspective view of the roller plate assembly of FIG. 2 .
- FIG. 5 is a partial, cross-sectional view of the roller plate assembly of FIG. 2 .
- a material handling system 10 is schematically illustrated in FIG. 1 .
- the material handling system 10 includes a first (upper) conveyor system 12 , a second (lower) conveyor system 14 , and a roller plate assembly 16 according to one embodiment of the invention positioned between the first and second conveyor systems 12 , 14 .
- boxes or packages 18 a , 18 b , 18 c are illustrated moving along the first conveyor system 12 , down the roller plate assembly 16 , and along the second conveyor system 14 .
- a transition member 20 may extend from the end of the first conveyor system 12 to bridge a gap between the discharge end 22 of the first conveyor system 12 and the roller plate assembly 16 .
- the box or package 18 b leaves the roller plate assembly 16 , it enters onto a receiving end 24 of the second conveyor system 14 .
- the roller plate assembly 16 is positioned at an angle 8 relative to the horizontal.
- the angle 8 should be at least 6 degrees, and preferably at least 8 degrees or greater.
- FIG. 1 illustrates the discharge end 22 of the first conveyor system being a distance D from the receiving end 24 of the second conveyor system.
- only one roller plate assembly 16 extends that distance D between the discharge end 22 of the first conveyor system 12 and the receiving end 24 of the second conveyor system 14 .
- Additional roller plate assemblies 16 may be connected along their long edges to accommodate a wider distance D between the discharge end 22 of the first conveyor system 12 and the receiving end 24 of the second conveyor system. Any number of roller plate assemblies 16 may be connected to span that distance D, such as more than 2 roller plate assemblies 16 , more than 10 roller plate assemblies 16 , or more than 20 roller plate assemblies depending upon the distance D between the discharge end 22 of the first conveyor system and the receiving end 24 of the second conveyor system 14 .
- the roller plate assembly 16 includes a base plate 30 with upper and lower surfaces 31 a , 31 b , cross supports 32 , roller shafts 34 , and rollers 36 .
- the base plate has a length L and a width W, as depicted in FIG. 2 .
- Fasteners such as screws 38 , may be used to secure the cross supports 32 to the lower surface 31 b of the base plate 30 .
- the screws 38 pass through holes 40 in the base plate and engage threaded holes in the top of the cross supports 32 .
- the screws 38 may be socket flat heads screws with 1 ⁇ 4-20 threads and may be zinc plated.
- roller shafts 34 pass through passages 42 in each of the five “inside” cross supports 32 .
- the ends of each roller shaft 34 terminate in the cross supports 32 a , 32 b , which are disposed at opposing ends of base plate, in passages 42 a , 42 b ( FIGS. 3 and 5 ) that do not pass all the way through the cross supports 32 a , 32 b .
- Each roller shaft 34 is a continuous piece extending from one end of the roller plate assembly 16 to the other.
- the passages 42 a , 42 b may go all the way through the cross supports 32 a , 32 b and the roller shafts 34 go through and extend out of the passages 42 a , 42 b .
- the roller shafts 34 may be held in place and prevented from moving relative to the cross supports 32 by split rings (not shown) which are inserted into holes at either end of the roller shaft 34 .
- Each roller 36 has a center hole 44 sized to allow the roller shaft 34 to be inserted therethrough and to allow the roller 36 to freely rotate about roller shaft 34 .
- the roller 36 may be made of any suitable material.
- the roller 36 may be made from ultra-high-molecular-weight (UHMW) polyethylene or polyoxymethylene (also known as acetal, polyacetal, polyformaldehyde, and paraformaldehyde) (sometimes sold under the tradename DelrinTM), for example.
- UHMW ultra-high-molecular-weight
- the roller 36 does not have a bearing or bushing in the center hole 44 . Instead, the roller 36 directly contacts the exterior surface of the roller shaft 34 .
- roller 36 made of UHMW or DelrinTM will run more quietly on the roller shaft 34 compared a roller with a bearing or bushing. Over time a roller with a bearing or bushing will become louder as the bearing or bushing wears, accumulates dirt, and starts to deteriorate. That increased noise may be problematic in a warehouse setting where there are many roller plate assemblies operating thereby subjecting workers to ever increasing and perhaps unsafe noise levels.
- the base plate 30 includes a plurality of openings 46 ( FIG. 3 ).
- a first group of openings 46 may be configured or sized to accommodate a single roller 36 therein and project at least partly over the upper surface 31 a of the base plate 30 .
- a second group of openings 46 may be configured or sized to accommodate at least two rollers 36 therein and project at least partially over the upper surface 31 a of the base plate 30 .
- the first group of openings 46 and second group of openings 46 may form an array of openings 46 in the base plate 30 extending in the length direction and width direction of the base plate.
- the array of different sized openings 46 are alternatingly positioned along the width of the base plate 30 so that in a section of the base plate 30 between the adjacent cross supports 32 there is a single roller 36 next to two adjacent rollers 36 on roller shaft 34 .
- the spacing of the different sized openings 46 and thus the rollers 36 associated with adjacent roller shafts 34 also alternate in the length of the base plate 30 .
- This alternating pattern of the different sized openings 46 is apparent in the base plate 30 shown in FIGS. 2 and 3 . It will be appreciated that other spacings may be used for the openings 46 to create different alternating patterns both along the roller shafts 34 and between adjacent roller shafts 34 .
- the openings 46 may be the same size or may be larger to accommodate three or more rollers 36 therein.
- the base plate 30 includes side flanges 50 which includes holes 52 .
- the roller plate assemblies 16 may be connected to each other by fasteners (e.g., nut and bolt) positioned in the holes 52 in the side flanges 50 of abutting roller plate assemblies 16 .
- the base plate 30 may be about 42 inches long and about 12 inches wide. It will be appreciated that the base plate 30 may have other lengths and widths depending upon the dimensions of the material handling system 10 and the gap and height difference between the first conveyor system 12 and the second conveyor system 14 .
- the thickness of the base plate 30 (including the side flange 50 ) may be about % of an inch, although other thicknesses may also be used.
- the base plate 30 may be made from either aluminum or stainless steel, although other gauges and materials may be used.
- the roller 36 may have an overall length in the range of 0.5-1.0 inches and preferably 0.817 inches and a diameter in the range of 0.5-0.9 inches and preferably 0.7 inches.
- the center hole 44 of the roller 36 may have a diameter in the range of 0.15 to 0.20 inches and preferably 0.168 inches.
- the roller shaft 34 may be made of alloy steel, although the roller shaft 34 may be made of any suitable material.
- the roller shaft 34 may have a diameter in the range of 0.10 to 0.19 inches and preferably 0.156 inches.
- the cross support 32 may be made from aluminum and preferably 6061 aluminum, although the cross support 32 may be made from any suitable material.
- the cross support 32 may have a square cross-section with each side being in the range of 0.5 to 1.0 inches and preferably 0.75 inches.
- roller plate assembly 16 may be sized to accommodate a particular material handling system 10 and/or the size and weight of the boxes/packages 18 a , 18 b , 18 c.
Abstract
Description
Claims (18)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/520,847 US11840404B2 (en) | 2020-11-13 | 2021-11-08 | Roller plate assembly |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202063113353P | 2020-11-13 | 2020-11-13 | |
US17/520,847 US11840404B2 (en) | 2020-11-13 | 2021-11-08 | Roller plate assembly |
Publications (2)
Publication Number | Publication Date |
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US20220153529A1 US20220153529A1 (en) | 2022-05-19 |
US11840404B2 true US11840404B2 (en) | 2023-12-12 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/520,847 Active 2041-12-21 US11840404B2 (en) | 2020-11-13 | 2021-11-08 | Roller plate assembly |
Country Status (1)
Country | Link |
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US (1) | US11840404B2 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7882945B2 (en) * | 2008-09-10 | 2011-02-08 | Robert Bosch Gmbh | Rolling conveyor with a drive assembly |
US20180237160A1 (en) * | 2015-08-17 | 2018-08-23 | John Bean Technologies Corporation | Loader for aircraft |
US10407259B2 (en) * | 2016-09-09 | 2019-09-10 | Kyung Ho Choung | Railway cargo delivery system |
-
2021
- 2021-11-08 US US17/520,847 patent/US11840404B2/en active Active
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7882945B2 (en) * | 2008-09-10 | 2011-02-08 | Robert Bosch Gmbh | Rolling conveyor with a drive assembly |
US20180237160A1 (en) * | 2015-08-17 | 2018-08-23 | John Bean Technologies Corporation | Loader for aircraft |
US10407259B2 (en) * | 2016-09-09 | 2019-09-10 | Kyung Ho Choung | Railway cargo delivery system |
Also Published As
Publication number | Publication date |
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US20220153529A1 (en) | 2022-05-19 |
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Owner name: CROWN PLASTICS CO., OHIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ELLERHORST, PETER;REEL/FRAME:058042/0822 Effective date: 20211105 |
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